Analysis Method of Friction Torque and Weld Interface Temperature during Friction Process of Steel Friction Welding

Abstract

This paper describes an analysis method of the friction torque and weld interface temperature during the friction process for steel friction welding. The joining mechanism model of the friction welding for the wear and seizure stages was constructed from the actual joining phenomena that were obtained by the experiment. The non-steady two-dimensional heat transfer analysis for the friction process was carried out by calculation with FEM code ANSYS. The contact pressure, heat generation quantity, and friction torque during the wear stage were calculated using the coefficient of friction, which was considered as the constant value. The thermal stress was included in the contact pressure. On the other hand, those values during the seizure stage were calculated by introducing the coefficient of seizure, which depended on the seizure temperature. The relationship between the seizure temperature and the relative speed at the weld interface in the seizure stage was determined using the experimental results. In addition, the contact pressure and heat generation quantity, which depended on the relative speed of the weld interface, were solved by taking the friction pressure, the relative speed and the yield strength of the base material into the computational conditions. The calculated friction torque and weld interface temperatures of a low carbon steel joint were equal to the experimental results when friction pressures were 30 and 90 MPa, friction speed was 27.5 s −1 , and weld interface diameter was 12 mm. The calculation results of the initial peak torque and the elapsed time for initial peak torque were also equal to the experimental results under the same conditions. Furthermore, the calculation results of the initial peak torque and the elapsed time for initial peak torque at various friction pressures were equal to the experimental results.

Experimental Thermal Analysis in Rotary Friction Welding of Dissimilar Materials

“…Due to the relevance of the topic, there are many experimental and analytical studies published by researchers from different parts of the world: Wei and Sun (2018), Dawood et al (2017), Ratkovic et al (2017), Rombault (2011), Aritoshi and Okita (2003), Khan (2011), Kuchuk-Yatsenko and Zyakhor (2002), Basher (2013), Yilbas and Sahin (2014), Fukumoto et al (2010), Nikolaev and Olshansky (1977), Seli et al (2010), Maldonado-Zepeda (2001), Cenk et al (2012), Moarrefzadeh (2012), Faizal et al (2014), Li et al (2012), Ruma et al (2013), Singla (2010), Kimura et al (2010) and Bouarroudj et al (2017), Burakowiski and Wierzchon (1998).…”

Research Status of Friction Interface Evolution Mechanism of Non-magnetic Steel

“…As the temperature continues to rise, the metal on the friction interface gradually plasticizes and forms a plastic ring, thereby achieving the purpose of welding [7,10,11]. At the end of the first stage of friction welding, the plastic ring has completed its nucleation process and successfully extended to the entire welding interface, thus laying a key foundation for joint forming [13][14][15][16][17].…”

“…In the study of Kimura [13,15], the influence of rotational speed on the position of plastic ring nucleus in friction welding process was deeply discussed. The position changes of the plastic annular nucleus under different rotational speeds were compared experimentally.…”

Effect of Friction Pressure on Microstructure and Properties of Friction Welded Joints of Pure Aluminum/304 Stainless Steel

“…The welding process can be divided into a friction stage and an upset stage, and the friction stage can be subdivided into two phases, namely an abrasion stage [13] and an adhesive friction stage [14]. At the beginning of welding, the protrusions on the interface wear and shear to generate frictional heat.…”